CATSKILL 1468 User manual

Assembly Instructions
Model 1468
Deep Drawer Double Drop Leaf Cart
GENERAL:
1. You have purchased model 1468.
2. Should you need assistance or need to replace a damaged or missing part simply give us a call M-F at
607-652-7321 from 7:30 am - 4:30 pm EST and we’ll send you the prepaid part via UPS usually that same day!
You may also email us [email protected].
3. Read the assembly instructions and the enclosed brochure before beginning assembly. Assembly is easy
if you read and follow the instructions step by step. See our website for assembly tips and videos:
www.catskillcraftsmen.com
4. The only tools needed are a hammer and a screwdriver. A power screwdriver is recommended. Where
possible we have packaged some of the screws in separate labeled packages. A friend is recommended to assist
with the assembly. Some parts are large and awkward to hold in place.
5. Glides are sometimes pre-packed with screws. These are not used.
6. Instructions (left/right, top/bottom) are given as you face an assembled unit.

Parts List Model 1468
Table Top (1)
P/N TT-1468
20” x 22” x 1 1/2”
Drop Leaf (2)
P/N DL-1468
20” x 12” x 1 1/2”
Right Front/Left Back Leg (2)
P/N Leg-1468 FR/BL
30” x 2 1/2” x 2 1/2”
Left Front/Right Back Leg (2)
P/N Leg-1468 FL/BR
30” x 2 1/2” x 2 1/2”
Top Side Braces (2)
P/N B-1469/TS
13” x 7.75” x 3/4”
Top Back Brace (1)
P/N B-1469/TBK
16 1/2” x 9” x 3/4”
Drawer Front (1)
P/N DF-1468
16 5/16” x 8 7/8” x 3/4”
Drawer Bottom (1)
P/N DBOT-1468
14 5/8” x 14 5/8” x 5/32”
Drawer Back (1)
P/N DBK-1468
15 1/2” x 7” x 3/4”
Drawer Side Left (1)
P/N DS-1468L
14” x 7” x 3/4”
Drawer Side Right (1)
P/N DS-1468R
14” x 7” x 3/4”
Glide Support Braces (2)
P/N GS-1468
13” x 2” x 3/4”
Slatted Wood Shelves (2)
P/N Shelf-1468
Pre-Assembled

1 1/4” Phillips Flat Head #8 Screw (12)
1” Truss Head Machine Screw (2)
5/8” Phillips Flat Head #8 Screw (32)
3/4” Long 3/16” DIA. Steel Pin (8)
Hinge (4)
Wheel
Casters (2)
Locking Wheel
Casters (2)
3/16” Flat Washer (2)
Bastion Set Screw (16)
Bastion Post (16)
Bastion Barrel Nut (16)
P/N Drop Leaf Support (2)
Full Extention
Drawer Glide (1 Set)
5/8” Phillips Flat Head #6 Screw (16)
Hardware List Model 1468
To ease assembly, sort and count the hardware before getting started.
(Drawer Backs
and Shelves)
(Attaches Hinges
Drop Leaf Supports)
(Used to attach L Brackets
and Drawer Glides)
(Attaches Handles
Top Drawer)
(Brace Pin)
L-Bracket (4)
Allen Wrench
Nickel Handle (1)
Caster Socket (4)

WRONG!
Post needs to be screwed deeper.
WRONG!
Post needs to be backed out.
CORRECT!
Set screw secures post properly.
Step 1
1. The Bastion fastening system consists of a steel post (threaded on one end with a hole
through the shaft on the other end); a Barrel Nut (cylindrical barrel-shaped with threaded
open end & holes through the sides); and a Set Screw (Phillips slot on one end, pointed on
the other)
2. To attach Posts: A) Dip threads of Post in vegetable oil. B) Align threaded end of Post
with hole in wood, tap on slotted end with hard hammer until threads enter, then tighten
down using a flat head screw driver or the provided allen wrench (See the Illus. Bas. 3 for
alternate seating methods). DO NOT TRY TO HAMMER THE POST ALL THE WAY IN AS IT
WILL STRIP THE POST HOLE. C) When solid shaft of Post hits wood, back out
approximately ½ turn until the hole in the posts is properly aligned as per step by step
directions. For example: the holes in the posts on the inside of the drawer front will be
parallel with the long length of the drawer front when properly seated.
3. A) Place a Barrel Nut into the nut access hole, so that the threads in the nut face out.
The small notches on either side of the nut opening, indicate the location of the holes
through the sides of the nut. B) Insert the posts through the end of the braces (or drawer
sides); through the holes in the sides of the nut. When properly aligned, you will see the hole
in the post inside the barrel nut. Post hole should be slightly off-center toward the wood.
4. Insert the Set Screw into the threaded end of the nut and tighten down. The tip of the Set
Screw will seek the center of the hole in the Post as it is tightened down, forcing the Nut
toward the main shaft of the Post. This is what tightens the wooden parts together. Set
screws should thread easily – DON’T CROSS THREAD! If Set Screw doesn’t thread easily,
check position of the hole in Post.
5. If the wooden parts are not tight against each other, the Post needs to be screwed a half
turn at a time until wood joints are tight.
Illustration Bas. 1
Step 2
Illustration Bas. 2 Illustration Bas. 3
TIPS ON HOW THE BASTION FASTENING SYSTEM WORKS
See video on our website!
If you have any questions regarding assembly or missing or damage
parts, call our customer support number:
607-652-7321 or 888-732-7321.
Customer Support Hours are 8am-5pm Mon. - Fri. Eastern Time zone.
Allen Wrench Provided

STEP 1
Assemble Side Panels
A. Each side panel consists of two (2) legs, one
(1) top side brace and one (1) glide support brace.
When assembled, diagonal legs will be the same
(i.e. Front Right/Back Left and Front Left/Back
Right). Side panels are identical when assembled -
the drawer glides will determine left and right sides.
B. Take each of the 4 legs and install two (2) Bastion
Posts per leg, on the side of the leg which also
has two (2) pin holes for the Glide Support Sticks.
Locate post holes. Tap Posts in with hammer until
threads engage wood; turn Posts down until the
solid shaft hits the wood (All threads are into wood),
then back Posts out until the holes in the Posts are
perpendicular to the long length of the leg (about 1/2
turn). Attach L-Bracket to the leg using 5/8” Phillips
Flat Head #6 Screw. Use the slot rather than the
hole on the L Bracket. The hole is used to fasten the
table top.
C. Lay out front leg and one (1) top side brace as
shown in Illustration 1A.
D. Take the top side brace and drop two barrel nuts
into the access holes as in Illustration 1A. Threaded
end of the nuts face out. Insert front left leg posts
into the holes in the ends of the brace, through the
side of the barrel nuts, until the holes in the posts
can be seen through the threaded end of the nuts.
Insert the Set Screws into the nuts and tighten
down. The tip of the set screw will seek the center
of the bastion post as it is tightened leaving a tight
joint. If the joint is too loose, check to make sure the
set screw is not cross-threaded or that the post is
out too far (not threaded into leg deep enough). See
previous page for Bastion illustrations.
E. Insert two 3/4” pins into each end of the glide
support brace. Position brace so that the pilot holes
for attaching the glide are towards the bottom edge.
Insert brace pins into the holes on the inside of the
left front leg as in Illustration 1B (4 pilot holes out)
with pilot holes off-center toward the bottom of the
leg.
F. Attach Back Left Leg in the same manner as in
Illustration 1C.
G. Repeat for other side panel.
Nut access holes
bottom shelf hole
TOP SIDE BRACE
Bastion Post
Illustration 1A
not used
in front legs
Left Front Leg
middle shelf hole
bottom shelf hole Illustration 1B
not used
in front legs
Left Front Leg
middle shelf hole
Pilot holes go on
the bottom edge
Illustration 1C
Left Front Leg
Left Back Leg

STEP 2
Attach Drawer Glides to
Glide Support Sticks
A. Take the Drawer Glides,
extend them to their fullest. See
illustration 2A. The glide has
3 parts. Remove the furthest
extended part (smallest) by
pushing the black plastic lever
down - then pull part out,
separating it. This part will attach
to the Drawer Side later. Attach
the largest parts to the Glide
Support Stick using holes as
illustrated. Attach with 5/8” #6 at
head screws. About 1 1/4” of this
glide will overlap the Front Leg.
See Illustration 2B.
B. Repeat with the other side. Illustration 2A
This end of the glide overlaps front leg 1 1/4”
& the bottom edge drops below the
glide support brace
Bastion Post positions
for Top Back Brace
Right Front Leg
Prepare Side Assemblies for Top Back Brace
The top back brace utilizes the bastion system for attachment. Place the bastion posts into their
positions on the back legs only of both side assemblies.
Push this lever down, then
slide the inner glide section
out of the glide assembly.
FRONT OF CART
Face of
Glide
Backside
of Glide
Use these two (2) holes to attach the glide to the side panel.

STEP 3
Attach The Top Back Brace
You may nd it easiest to attach the Top Back Brace and shelves by inverting the island.
The Top Side Braces are located 1 1/4” down on the legs. This allows clearance for hinges and
the drop leaf supports. Attach the Top Back Brace to the left and right side panels with bastions.
Top Edge Should be 1 1/4 in. space from
top of brace to top of cart.
STEP 4
Tabletop Preparation
Invert the Table Top on smooth at surface. Attach the 4 hinges with 5/8” #8 screws. Large part of
hinges go on drop leaf. Attach the drop leaf supports with 5/8” #8 screws.

STEP 5
Attach Legs to Table Top
With top still inverted line up
pilot holes with hole in the
L Brackets and secure top
to leg assembly with 5/8” #6
screws.
STEP 6
Attach Casters, Middle and Bottom Shelves
With unit still upside down, tap caster sockets into holes in leg ends until seated, then tap casters.
Hit on metal part of caster to seat. Locking casters usually go on the front, non-locking casters on the
back. Use 1 1/4” #8 screws to attach the shelf to the inside of the 4 legs.

STEP 7
Assemble Drawer
A. Attach the drawer back to the drawer sides with 1 1/4” #8 screws. Slide in drawer bottom, best side
up. Attach front using the Bastion System. Holes in the posts will be parallel to the long edge of the
drawer front. See illustration.
B. Attach the drawer glide to the drawer sides with 5/8” #6 screws in the places indicated in the illustra-
tion. Black plastic lever will face outward. Glide will be up against the back of the drawer front.
C. After you have the drawer assembled simply upright the unit and attach the drawer to the cart by
sliding it into the Glide Rails. Drawer glides will lock into place.

For continued beauty and long life
of your Catskill Craftsmen cart, we
recommend Catskill Craftsmen’s
Butcher Block Oil. Our Butcher Block
Oil is available directly from Catskill
Craftsmen’s factory. For one eight
ounce (8 . oz.) bottle, which is
sufcient for two applications, simply
send $7.95 along with the completed
coupon to the address below. Visit
us online at www.catskillcraftsmen.
com to browse our assortment of
butcher block care products. Visa and
Mastercard are accepted online.
Catskill Craftsmen, Inc.
15 West End Ave.
Stamford, NY 12167-1296
BUTCHER BLOCK OIL COUPON
Please send me______ # of bottle(s) of the
Catskill Craftsmen Butcher Block Oil at $7.95
per bottle. My check or money order is
enclosed for a total of $_______________.
Item code: 1468
Name _______________________________
Address _____________________________
City ________________________________
State ________________ Zip ___________
Please make checks payable to Catskill Craftsmen Inc.
15 West End Ave., Stamford, NY 12167-1296